Toyota PT925-42160 User manual

TOYOTA RAV4 (Gas Only) 2016 - 2018 RUNNING BOARDS
Preparation
Page 1 of 14 pages
Issue: C07/27/2017
DIO
Part Number: PT925-42160
Kit Contents
Item #
Quantity Reqd.
Description
1
1
LH Board Assembly
2
1
RH Board Assembly
3
1
LH Rear Mounting Bracket
4
1
RH Rear Mounting Bracket
5
2
Front Mounting Bracket
6
2
Front Pinch Weld Bracket
7
1
Jack Block
8
1
Jack Decal
9
1
Pinch weld Drill Templates
10
1
Hardware Bag
11
1
Owner’s Manual Decal
Hardware Bag Contents
Item #
Quantity Reqd.
Description
1
2
M12 Frame Locking Bolt
2
2
M12 Serrated Flange Nut
3
2
M8 U-Bolt
4
2
M8 Carriage Bolt
5
6
M8 Serrated Flange Nut
6
4
M5 SEMS bolt w/lead in tip
7
4
M5 Flange Nut
8
8
M8 Serrated Flange Bolt
9
4
#12 x ¾” Tech Screw
Additional Items Required For Installation
Item #
Quantity Reqd.
Description
1
2
3
4
Conflicts
Hybrid & Adventure Package Models
General Applicability
2016 & later RAV4 gas models, except Adventure Package
Recommended Tools
Personal & Vehicle
Protection
Notes
Special Tools
Notes
Installation Tools
Notes
Ratchet
3/8"
Shallow Sockets
8mm, 10mm (1/4” Drive)
Deep Sockets
13mm, 18mm (3/8” Drive)
Extension
3" long (⅜” Drive)
6” long (¼” Drive)
Socket Adapter
3/8” Drive to 1/4” Drive
Combination Wrench
8mm
Torque Wrench – Ft Lbs / Nm
3/8" Drive (3-60 ft lbs/ 4-81 Nm)
Center Punch
Drill Motor
3/8" Drive
Drill Bit
5.5mm Bit (7/32”)
Plastic Scraper Tool
Plastic pry tool
Allen Socket
3mm (1/4” Drive)
Deburring Tool
Special Chemicals
Notes
Sealer
3M Pro Auto Body Sealant
Recommended Sequence of Application
Item #
Accessory
1
Mudguard
2
Running Boards
*Mandatory
Vehicle Service Parts (may be required for reassembly)
Item #
Quantity Reqd.
Description
Legend
STOP: Damage to the vehicle may occur. Do not
proceed until process has been complied with.
OPERATOR SAFETY: Use caution to avoid risk of
injury.
CAUTION:
A process that must be carefully observed
in order to reduce the risk of damage to the
accessory/vehicle and to ensure a quality installation.
TOOLS & EQUIPMENT:
Used in Figures calls out the
specific tools and equipment recommended for this
process.
REVISION MARK: This mark highlights a change in
installation with respect to previous issue.
SAFETY TORQUE: T
his mark indicates that torque is
related to safety.

TOYOTA RAV4 (Gas Only) 2016 - 2018 RUNNING BOARDS
Procedure
Page 2 of 14 pages
Issue: C07/27/2017
DIO
Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this
accessory should follow approved guidelines to ensure a quality installation.
These guidelines can be found in the "Accessory Installation Practices" document.
This document covers such items as:-
•Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.).
•Safety (eye protection, rechecking torque procedure, etc.).
•Vehicle Disassembly/Reassembly (panel removal, part storage, etc.).
•Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.).
Please see your Toyota dealer for a copy of this document.
1. Prepare for the Installation.
(a) Lay out the parts to check for damage.
Check the hardware bag contents for correct
type and quantity (Fig. 1-1).
(b) Read and understand the entire installation
instructions prior to beginning.
(c) The running boards and rear brackets are side
specific. The larger end cap of the running
board goes to the vehicle front. The rear
brackets are marked as LH and RH for side
designation.
RH
Fig. 1-1
FRONT
FRONT
LH

TOYOTA RAV4 (Gas Only) 2016 - 2018 RUNNING BOARDS
Procedure
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Issue: C07/27/2017
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2. Remove Parts and Drill.
(a) Open all four doors before lifting the vehicle
to allow access for drilling the pinch welds.
(b) Remove and discard the left and right rear
diffusers. Use a 10mm socket to remove the
retaining screw (Fig. 2-1).
(c) Insert the blade of a plastic pry tool forward
between the diffuser and the underbody.
Carefully push in the tab from the top side of
the tab downward and slide the diffuser out
towards the rear wheel (Fig. 2-1).
(d) Remove and save the right hand plastic
undercover and hardware for reattachment.
Use a 10mm socket to loosen the three
attachment nuts and remove the three push
pins (Fig. 2-2).
(e) Remove the two Mylar hole covers on both
left and right front underbody to access the
front mounting bracket upper attachment
holes (Fig. 2-3).
NOTE:Use a plastic scraper tool or equivalent
to remove any body sealer around the two upper
front mounting holes that may restrict the
mounting bracket from seating into position (Fig.
2-3).
Fig. 2-1
10 mm socket & ratchet, plastic pry tool
Pry tool
10 mm socket
Fig. 2-2
Front
Push pins
10 mm socket, extension & ratchet, plastic pry tool
10 mm socket
Body sealer
Mylar covers
Fig. 2-3
Plastic scraper

TOYOTA RAV4 (Gas Only) 2016 - 2018 RUNNING BOARDS
Procedure
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(f) Locate the front and rear pinch weld drill
template positions (Fig. 2-4).
(g) Remove the pinch weld drill template from
the white paper backing and install the
template along the jacking point of the pinch
weld.
(h) Align the lower edge of the drill template
with the bottom of the pinch weld and follow
the outer most sheet metal contour (front,
Fig. 2-5 and rear, Fig. 2-6).
NOTE:Verify the template notches are in the
correct position as shown in Fig. 2-5 and Fig. 2-
6.
(i) Ensure the center of hole is 8.5mm above the
bottom of the pinch weld. Mark the center of
the hole with a center punch.
NOTE: The position of the Sticky Template is
important. Care should be taken to ensure proper
positioning before drilling the holes. The
brackets can be held in mounting position to
verify that all mounting and pinch weld holes
align properly before drilling.
(j) Use a 5.5mm diameter drill bit to drill holes
in the front and rear pinch weld location.
(k) Remove the drill templates and deburr the
holes of any metal shavings from both sides.
Forward
Fig. 2-4
Pinch Weld Drill Template Positions
Rear
Front
Rear position
Forward
Fig. 2-5
3/8” drill with 5.5mm drill bit
8.5mm
Fig. 2-6
Forward
Front position
3/8” drill with 5.5mm drill bit
8.5mm

TOYOTA RAV4 (Gas Only) 2016 - 2018 RUNNING BOARDS
Procedure
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3. Install the Front Left Hand Bracket to the
Vehicle.
NOTE: If needed, remove any OEM pinch weld
sealant that may interfere with the proper
installation of mounting hardware and/or
components.
(a) Apply body sealant to the drilled 5.5mm
hole.
(b) Align the pinch weld bracket to the outside
of the pinch weld. Install a M5 SEMS bolt
from the inside drilled pinch weld hole
outward through the bracket forward hole.
Finger tighten the nut (Fig. 3-1).
(c) Install a plastic retaining clip to the midpoint
of the threads on a M8 U-bolt (Fig. 3-2).
NOTE:Be sure to align the secondary retaining
notch facing inward of the U-bolt as shown in
Fig. 3-2.
(d) Hold the plastic retaining clip and guide the
U-bolt through the upper front mounting
bracket holes (Fig. 3-3).
Fig. 3-3
Fig. 3-2
Fig. 3-1
Forward
Rear pinch weld

TOYOTA RAV4 (Gas Only) 2016 - 2018 RUNNING BOARDS
Procedure
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(e) Swing the plastic retaining clip over to the
other side of the U-bolt and connect the
secondary retaining notch to the U-bolt (Fig.
3-4).
(f) With the plastic U-bolt retaining clip firmly
in place, align the front bracket upper
mounting holes with the U-bolt and guide the
bracket into place (Fig. 3-5).
(g) Loosely install the two M8 flange nuts to the
U-bolt until the U-bolt just passes through
nut.
(h) Remove the plastic U-bolt retaining clip by
releasing the secondary retaining notch, then
twist and pull the clip out.
NOTE: Save the plastic retaining clip for use on
the right side installation.
(i) Swing the front mounting bracket up to the
pinch weld bracket and attach a M8 carriage
bolt finger tight (Fig. 3-6).
(j) Snug all front mounting bracket hardware
(M5 and M8).
NOTE:Make sure that the bracket is parallel to
the ground. It is important to tighten the U-bolt
nuts in equal increments from side to side.
(k) From the inside, torque the front M5 bolt to 5
N-m (48 in-lb).
Torque: 5 N-m (48 in-lb)
Fig. 3-4
Fig. 3-5
Forward
Fig. 3-6
M8 carriage bolt
M5 bolt
M8 U-bolt
8mm socket, 13mm
deep socket & ratchet

TOYOTA RAV4 (Gas Only) 2016 - 2018 RUNNING BOARDS
Procedure
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(l) Torque the M8 carriage nut to 23 N-m (17 ft-
lb).
Torque: 23 N-m (17 ft-lb)
(m)Torque both front bracket U-bolts in 3 steps:
7 N-m (60 in-lb), 14 N-m (10 ft-lb) and a
final torque of 23 N-m (17 ft-lb).
1st Step: Torque: 7 N-m (60 in-lb)
2nd Step: Torque: 14 Nm (10 ft-lb)
3rd Step: Torque: 23 N-m (17 ft-lb)
NOTE:It is important to tighten the U-bolt nuts
in equal increments from side to side.
4. Install the Rear Left Hand Bracket to the
Vehicle.
NOTE: If needed, remove any OEM pinch weld
sealant that may interfere with the proper
installation of the mounting hardware and/or
components.
(a) Apply body sealant to the drilled 5.5mm
hole.
(b) Insert a M12 frame locking bolt into the rear
tie-down hole on the vehicle with the long
section of the frame locking tab towards the
rear of the vehicle (Fig. 4-1).
Follow this
torque sequence
Fig. 4-1
Rear

TOYOTA RAV4 (Gas Only) 2016 - 2018 RUNNING BOARDS
Procedure
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(c) Insert the short side up into the hole
completely and slide the bolt forward (Fig. 4-
2).
NOTE:Verify that the frame locking bolt tab is
completely inserted into the mounting hole
before continuing to the next step.
(d) Guide the M12 frame locking bolt through
the hole in the rear mounting bracket and
finger tighten a M12 flange nut (Fig. 4-3).
(e) Swing the rear bracket up to the pinch weld.
Install a M5 SEMS bolt from the inside
drilled pinch weld hole outward through the
bracket. Finger tighten the nut (Fig. 4-4).
(f) From the inside, torque the M5 SEMS bolts
to 5.5 N-m (48 in-lb).
Torque: 5.5 N-m (48 in-lb)
(g) Torque the rear bracket M12 nut to 81 N-m
(60 ft-lb).
Torque: 81 N-m (60 ft-lb)
Fig. 4-3
Fig. 4-3
Fig. 4-2
Fig. 4-4
8mm socket & wrench, 18mm socket and ratchet

TOYOTA RAV4 (Gas Only) 2016 - 2018 RUNNING BOARDS
Procedure
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Issue: C07/27/2017
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5. Install the Left Hand Running Board to the
Bracket.
NOTE: The running boards are side specific. The
larger end cap goes to the FRONT of the vehicle.
NOTE: If the vehicle does not have mudguards,
skip to Step 5(d).
NOTE: If the running boards are installed with
mudguards, it is necessary to adjust the front end cap
position. Follow Steps 3(a) - 3(c).
(a) Remove the 2 tech screws from the front end
cap (Fig. 5-1).
(b) Push the end cap in until the forward set of
the end cap mounting holes align with the
holes in the running board (Fig. 5-2).
(c) Replace the tech screws. Use the provided
replacement screw (Fig. 5-2).
NOTE: Start here if the vehicle does not have
mudguards.
(d) Close the vehicle doors.
(e) Slide the gap guard to the front end cap (Fig.
5-3).
NOTE: The gap between the gap guard and the
rear end cap is normal, especially when installed
without a mudguard.
(f) Slide the two running board nut locators to
the center of the running board (Fig. 5-4).
Fig. 5-4
Nut locators
Fig. 5-3
Fig. 5-2
Tech screws
Push end cap
Fig. 5-1
Tech screws

TOYOTA RAV4 (Gas Only) 2016 - 2018 RUNNING BOARDS
Procedure
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(g) Set the running board onto the brackets, tilt
the board and slide it inward (Fig. 5-5).
(h) Align the rear edge of the running board with
the edge of the fender flare (Fig. 5-6).
(i) Slide the running board nut locators to the
edge of the mounting brackets and pull the
locators out of the track nuts. Use the end of
the locator to slide the track nuts into
position, lining it up with the holes in the
mounting bracket.
(j) Loosely install four M8 flange bolts into the
track nuts.
(k) Align the bolts to the outer-most slot position
and torque the four flange bolts to 23 N-m
(17 ft-lb).
Torque: 23 N-m (17 ft-lb)
6. Install the Right Hand Side Brackets and
Running Boards.
(a) Repeat Steps 2 through 5 for the right hand
side installation.
Fig. 5-6
Align edge
of board
with fender
flare
Fig. 5-5